Sustainable Brewing Systems, Practicesand Technology

Jazmine Bennett Jarett DiamondGary Fischer Kerby Smithson

Outline for Today

• Why Sustainable Craft Breweries?

• How:

– Inventory

– Measure

– Analyze

– Implement

– Monitor & Evaluate

• Our Findings

Google search terms to locate online resources

Introduction Why Sustainability? How Our Findings Conclusions

What is Sustainability?

“Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.”- Our Common Future, Brundtland Commission (1987)

Introduction Why Sustainability? How Our Findings Conclusions

Customers Demand It

Introduction Why Sustainability? How Our Findings Conclusions

You Can Save Money*

*If you’re smart about it

Introduction Why Sustainability? How Our Findings Conclusions

A Culture of Sustainability

Embody the vision of the world in which you want to live

Introduction Why Sustainability? How Our Findings Conclusions

Building Facts• 9,000 sq. ft. building in Ypsilanti, MI (c. 1948)• Opened 2006• Located in Historic District (restrictions apply)• Community events venue• Must preserve aesthetics

Brewing Facts• 3,000 BBl./yr• Currently distributes in Michigan• Major expansion planned this year

• Energy upgrades• Capacity expansion

Rene and Matt Greff

Introduction Why Sustainability? How Our Findings Conclusions

Understand Current Practices

Energy/Water Efficiency

On-Site EnergyGeneration

Engage Customer

BaseCost-Benefit Analysis

Our Scope

Introduction Why Sustainability? How Our Findings Conclusions

Step 1. Inventory Resources

Washington energy workbook

Energy and Water

Audit form includes tools to evaluate:• Food preparation• Cooling plant• Heating plant• Domestic hot water• Food preparation• Lighting• Renewable resource potential

Introduction Why Sustainability? How Our Findings Conclusions

Start with Utility Bills

Introduction Why Sustainability? How Our Findings Conclusions

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Useful Excel Functions

Energy: Pull Apart the Pieces

Introduction Why Sustainability? How Our Findings Conclusions

Cooling

Moving Lighting

Heating

Energy: Cooling

• Brewhouse Glycol Chiller

• Cold Room Chiller

• Air Handler

Introduction Why Sustainability? How Our Findings Conclusions

Fermentation vesselsCold Liquor Tank

Cold storage/refrigeration

Space cooling

Energy: Heating

• Boiler

• Air Handler

• DHW Heater

• Ovens, Grills

Introduction Why Sustainability? How Our Findings Conclusions

Brew kettleMash/lauter tun

Space Heating

Domestic HWBottling line ?

Food Cooking

Energy: Lighting

• Brewhouse

• Pub

• Outdoor (perimeter, parking)

Introduction Why Sustainability? How Our Findings Conclusions

Energy: Moving

• Pumps

• Mixers

• Motors

• Delivery vehicles

Introduction Why Sustainability? How Our Findings Conclusions

Water

• Brewhouse

– Mash and sparge

– Cleaning

– Bottling

• Pub

– Drinking

– Cooking

– Cleaning

• Lavatories

– Toilets

– Sinks

• Other

– Property irrigation

Introduction Why Sustainability? How Our Findings Conclusions

Step 2: Measure

• Take measurements and make estimates to develop your model

Introduction Why Sustainability? How Our Findings Conclusions

Building Envelope Study

• Some fixes are easy

• Blower door test

• Thermal imaging

• Energy modeling

– *Hire a professional to do

safety related items

Introduction Why Sustainability? How Our Findings Conclusions

Onset computer

HOBO U9 Motor On/Off Data Logger - U9-004Cheap and easy to use!

Introduction Why Sustainability? How Our Findings Conclusions

Sensor InstallationDomestic Hot Water Boiler

MotorsPumps

Introduction Why Sustainability? How Our Findings Conclusions

Air duct

Temp probe

Space Heating: Measure Temperature

Gradstudent

Space Heating

Logger

Introduction Why Sustainability? How Our Findings Conclusions

Space Cooling: Measure Air Handler Compressor & Fan Currents

Rated shock-resistant gloves

Weather-sealed datalogger (HOBO U12-008)

Introduction Why Sustainability? How Our Findings Conclusions

Professional HVAC Engineer

Rooftop Air Handler

Current Amplifier Datalogger

Chiller: Measure Compressor Current, Coolant Flowrate

Chiller

TCVQ

Introduction Why Sustainability? How Our Findings Conclusions

Heat Transfer Equation

Challenges with Motor On/OffState Data Loggers

Small pumps

Portable devices

Vibrating devices

Introduction Why Sustainability? How Our Findings Conclusions

Introduction Why Sustainability? How Our Findings Conclusions

Know:• Gas input rate• Time boiler is on• Qty beer brewed

On

Off

Pre-heat HLTMash-In

Sparge/Vorlauf/Boil

Boiler Fan

Energy Intensity

Natural Gas Barrel of Beer

Download Data

Step 3: Analyze Data

Other Tools for Analysis

PVWatts EERESketchUp

Introduction Why Sustainability? How Our Findings Conclusions

• Federal Energy Management Program (FEMP)

• Industrial Technologies Program (ITP) BestPractices

• (see Tip Sheets)

Baseline 3D model courtesy Patrick Reynoldsand Philip Proefrock

Financial Incentives

DSIRE

Introduction Why Sustainability? How Our Findings Conclusions

Introduction Why Sustainability? How Our Findings Conclusions

20 kW Solar Electric Project*

Payback Time: Almost Never

* 15 Year Loan4.75% Interest

Introduction Why Sustainability? How Our Findings Conclusions

Detroit Edison REC Payment (incl. taxes)

Payback Time: 5 Years

76% of NPV Costs RecoveredIn First Year

20 kW Solar Electric Project* + Incentives

Federal ITC Tax Grant

* 15 Year Loan4.75% Interest

Weigh Options

Introduction Why Sustainability? How Our Findings Conclusions

Small investmentsSmall returns

Big investmentsBig returns

User-Friendliness

Prioritize Options

Benefit – CostCost

Greater Number is

Higher Priority*

* All other things being equal!

Introduction Why Sustainability? How Our Findings Conclusions

Energy Conservation Measures

LBNL brewery

Required Reading Sample Topics

Energy Efficiency Improvement and Cost Saving Opportunities for Breweries. An ENERGY STAR® Guide for Energy and Plant Managers (LBNL 2003)

• Brewkettle heat recovery• Steam recompression• Wort stripping• Employee tasks

A Self-Assessment Workbook for Small Manufacturers v2.0 (Rutgers 2003)

• Pipe and roof insulation• Boiler combustion adjustment• Boiler exhaust stack heat recovery• Lighting efficiency

Rutgers self assessment

Find the solutions that work for your breweryIntroduction Why Sustainability? How Our Findings Conclusions

Water Conservation MeasuresRequired Reading Sample Topics

Reducing Water and Effluent Costs in Breweries (various UK brewing industry entities 1998)

• Comprehensive water and wastewater management program

Beer Production - Audit and Reduction Manual for Industrial Emissions and Wastes (UN Environmental Program 1998)

• Water use reduction• Wastewater COD and SS load reduction

Technical Pollution Prevention Guide for Brewery and Wine Operations in the Lower Fraser Basin (El Reyes Env. Grp 1997)

• Solid, liquid, gaseous pollution reduction measures

Beer production audit

http://tinyurl.com/beerwater

Find the solutions that work for your brewery

technical pollution

prevention guide brewery

Introduction Why Sustainability? How Our Findings Conclusions

Step 4: Implement

Introduction Why Sustainability? How Our Findings Conclusions

Step 5: Monitoring & Evaluation

• Monitor for continual improvement

• Evaluate success of projects

• Uncover new opportunities

• Data to share with employees & public

Introduction Why Sustainability? How Our Findings Conclusions

Energy Management System (EMS)

• One of the most successful and cost-effective ways to improve energy efficiency.

• Creates a foundation for improvement, provides guidance for managing energy throughout an organization.

Guidelines for Energy Management

Introduction Why Sustainability? How Our Findings Conclusions

Our Findings

Introduction Why Sustainability? How Our Findings Conclusions

(may not fit your specific needs)

Electricity

Understand rate structure• Call Utility Representative• Time of use charge?

(aka “demand charge”)• Ratchet charges?

Introduction Why Sustainability? How Our Findings Conclusions

Look for patterns

Electricity Use

Introduction Why Sustainability? How Our Findings Conclusions

Introduction Why Sustainability? How Our Findings Conclusions

265

270

275

280

285

290

295

300

305

0

500

1000

1500

2000

2500

3000

25 30 35 40 45 50 55

Ave

rag

e W

ee

kly

Dry

Bu

lb T

em

p (

de

gK

)

En

erg

y (

kW

h)

Week Number

Weekly Glycol Chiller Compressor Energy Usage (kWh)Scales with Ambient Temperature

Compressor Energy Used Each Week (kWh)

Weekly Avg Temp (degK)

No Data(interpolated)

Power outage7/23-7/25

June DecJul Aug Sep Oct Nov

Up to 40% of summer electric

Introduction Why Sustainability? How Our Findings Conclusions

Natural Gas

Introduction Why Sustainability? How Our Findings Conclusions

Look for patterns

Natural Gas Use

Introduction Why Sustainability? How Our Findings Conclusions

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

0 2 4 6 8CC

F U

se

d i

n B

rew

ing

Cycle

BBl in Brewing Cycle

CCF per BBl vs. # Batches in Cycle

Consecutive Batches

Est. CCF/BBl

1 2.75

2 2.45

4 2.15

8 1.85

Heat Exchanger Saves Gas(but, how much?)

Introduction Why Sustainability? How Our Findings Conclusions

Water

Introduction Why Sustainability? How Our Findings Conclusions

Water

Conclusion: a lot of water is being used for something to do with beer sales…

Introduction Why Sustainability? How Our Findings Conclusions

Our Top Picks for Corner Brewery: Building & Energy

• Energy Management System• Process Integration and Automation• Maintenance• Solar PV• Pipe Insulation• Upgrade heat exchanger• Brewkettle heat recovery• Boiler flue stack heat recovery• WTW heat pump for process cooling and heating• High-efficiency halogen and fluorescent lights• Double pane windows or operable shutters• Optimize ceiling fan use

Introduction Why Sustainability? How Our Findings Conclusions

Maintenance

Introduction Why Sustainability? How Our Findings Conclusions

Steam System Improvements

• Minimize excess air

• Clean boiler heat transfer surfaces

• Install heat recovery equipment (feedwater economizers and/or combustion air preheaters)

• Improve water treatment to minimize boiler blowdown

• Recover energy from boiler blowdown

• and more…

See Improving Steam System Performance:

A Sourcebook for Industry

Guidelines for Energy Management

Introduction Why Sustainability? How Our Findings Conclusions

Upgrade Heat Exchanger

• Multiple stage heat exchanger can recover up to 35-36 kBTU/BBl wort cooled

• Corner Brewery’s single stage heat exchanger is recovering 19 kBTU/BBl wortcooled

Source: Hackensellner (2000)

Introduction Why Sustainability? How Our Findings Conclusions

Solar Electric

95x Evergreen 210W Polycrystalline Panels 83x Thistle 240W Monocrystalline Panels

Introduction Why Sustainability? How Our Findings Conclusions

Waste Heat Recovery

• Brewkettle and Boiler Flue Stack Heat Recovery

• Integrated systems, e.g. New Belgium Brewing Co.

• Existing systems can be retrofitted with this feature.

Introduction Why Sustainability? How Our Findings Conclusions

Method Example Used by

Direct Heat Exchanger Spray condenser Soo Brewing Co – Sault Ste. Marie, Michigan

Indirect Heat Exchanger Economizer Atwater Block Brewing Co– Detroit, MI

Water-to-Water Heat Pump

Introduction Why Sustainability? How Our Findings Conclusions

Simultaneous heating and cooling

HeatHeat

Our Top Picks for Corner Brewery: Water

• Submetering

• Low-flow faucets

• Low-flow or dual flush toilets

• Wastewater biogas

• Rainwater collection for irrigation

Introduction Why Sustainability? How Our Findings Conclusions

Wastewater Biogas

Introduction Why Sustainability? How Our Findings Conclusions

Other Possibilities for Your Brewery

• Programmable thermostats

• Insulation

• Solar awnings

• High-volume low-speed fans (HVLS)

• Cogeneration

• Greywater

• Natural lighting

• Occupancy sensors

• Dimmable CFLs, LEDs, cold cathode

• Drop-lighting

• Geothermal

• Solar hot water

Introduction Why Sustainability? How Our Findings Conclusions

Education & Engagement Program

Introduction Why Sustainability? How Our Findings Conclusions

Education & Engagement Program

Employee Education

What do you want them to

know?

Fundamentals for Projects &

Feedback

“Pre-Test” Surveys

Introduction Why Sustainability? How Our Findings Conclusions

Education & Engagement Program

Customer Engagement

Events

Signage/Displays Learning Areas

Experience

Introduction Why Sustainability? How Our Findings Conclusions

Resources forEnvironmental & Sustainability

Employee Education

Introduction Why Sustainability? How Our Findings Conclusions

www.neefusa.org

Business & Environment Tab

Summary

• Sustainability & Craft Breweries

• 5 Steps to Greater Sustainability

– Inventory

– Measure

– Analyze

– Implement

– Monitoring & Evaluation

• Engagement

Introduction Why Sustainability? How Our Findings Conclusions

Thanks To…

• Craft Brewers Association

• Matt & Rene Greff

• Corner Brewery Staff

• University of Michigan School of Natural Resources & Environment

Introduction Why Sustainability? How Our Findings Conclusions

Jazmine BennettJarett DiamondGary FischerKerby Smithson

A Few Good Books• Herzog, Peter. Energy-Efficient

Operation of Commercial Buildings: Redefining the Energy Manager’s Job. McGraw-Hill, 1997

• Wang, Lijun. Energy Efficiency and Management in Food Processing Facilities. CRC Press, 2009.

• Masters, Gilbert. Renewable and Efficient Electric Power Systems. John Wiley & Sons, 2004.

• Lewis and Bamforth. Essays in Brewing Science. Springer, 2007.

• Briggs, et al. Brewing: Science and Practice. WoodheadPublishing, 2004.

Solar Photovoltaic 1

Payback Year 5

Year 1 PV Gross Savings

$64,210

Annual Car-Years of CO2 Offset

4

83x Thistle 240W Monocrystalline Silicon Photovoltaic Panels

Solar Photovoltaic 2

Payback Year 6

Year 1 PV Gross Savings

$67,120

Annual Car-Years of CO2 Offset

4

95x Evergreen 240W Polycrystalline Silicon Photovoltaic Panels

Solar Hot Water

Payback Year 9

Year 1 PV Gross Savings

$25,016

Annual Car-Years of CO2 Offset

3

20x Apricus AP-30 Evacuated Tube Solar Thermal Panels

Introduction Why Sustainability? How Our Findings Conclusions

Geothermal Heating and Cooling

• ~55 degF at six feet under

• Ideal for applications with simultaneous heating and cooling

• High up-front costs

Introduction Why Sustainability? How Our Findings Conclusions

Two Cogeneration Technologies

Microturbine

• Natural gas, propane

• 30 kWe minimum capacity

• Smaller turbines being developed

Fuel Cell

• Natural gas, biogas, propane, hydrogen, methanol

• Proton Exchange Membrane

• Solid Oxide Fuel Cell

Introduction Why Sustainability? How Our Findings Conclusions

Greywater

Introduction Why Sustainability? How Our Findings Conclusions

Introduction Why Sustainability? How Our Findings Conclusions

Payback Time: Never

Solar Electric Project

(Without financing or incentives)

Energy Efficiency Measures for Steam Systems

(shorter bars are better)Source: Einstein, et al. Steam systems in industry: Energy use and energy efficiency

improvement potentials. Lawrence Berkeley National Laboratory. Paper LBNL-49081.